3 WG-116/131/161/171 - forkliftcenter.com · The ZF-Transmissions 3 WG-116/131/161/171 are composed...

Order-No.: 5872 363 002

ZF – ERGOPOWER TRANSMISSION

3 WG-116/131/161/171

TECHNICAL DATADESCRIPTIONOPERATIONMAINTENANCEDIAGNOSTIC SYSTEMS

ZF Passau GmbHDonaustr. 25 - 71 Edition: 2003/09D - 94034 Passau Subject to changes w/o notice !

ERGOPOWER GeschäftsbereichArbeitsmaschinen-Antriebeund Achssysteme

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1. Edition


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Preface

The present Documentation has been developped for skilled personnel which has been trainedby the ZF for the Maintenance and Repair operations on ZF-units.However, because of technical development of the product, the Maintenance and Repair of theunit in your hands may require differing steps as well as also different setting and test data.

This Manual is based on the technical state at the printing.At the preparation, every possible care has been taken to avoid errors.However, we are not liable for possible mistakes concerning the representation and the des-cription.

We are reserving ourselves the right of modifications without previous information.

The responsibility lies with the owner and the user, to pay attention to the safety indications,and to carry out the Maintenance operations according to the prescribed Specifications.

The ZF is not liable for faulty installation, incorrect treatment, insufficient Maintenance, im-pro-perly and unskilled performed works, and for the subsequential damages resulting from it.

It is imperative to pay attention to the corresponding Specifications and Manuals of the Ve-hicle Manufacturer.

Important Informations concerning the technical reliability and reliability in service are accen-tuated by the following Symbols:

��Valid for Instructions which must be observed at the Maintenance, the Perfor-mance or the Operation of the vehicle !

Is inserted at working and operating procedures which have to be exactly res-pected to avoid a damage or destruction of the unit or to exclude a danger topersons !

ERGOPOWER

Off-Road Transmissions and Axle Systems Division

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TABLE OF CONTENTS Page: Summary of the TECHNICAL DATA 6 - 7 Type plate 8 IMPORTANT INSTRUCTIONS 9 - 10 I. DESCRIPTION 11 1.1 Function of the Converter 1.2 Powershift transmission 1.3 Transmission control 1.4 Controllers 1.4.1 General 1.4.2 Controller DW-3 1.4.3 Controller ERGO II 1.5 Display 1.5.1 General 1.5.2 Possible Indications on the Display 1.5.3 Error code definition 1.6 Electronic control unit TCU 1.7 Electronic control for the ZF-Powershift transmission 1.7.1 General 1.7.2 Description of the Basic functions 1.7.3 AEB 1.7.4 Downshifting functions (Down-Shift Button) 1.7.5 Pressure cut-off 1.7.6 Inching device 1.7.7 Special functions II. INSTALLATION SPECIFICATION 25 III. OPERATION 27 3.1 Driving preparation and Maintenance 3.2 Driving and Shifting 3.3 Cold start 3.4 Transmission control in the Driving range Automatic 3.5 Stopping and Parking 3.6 Towing 3.7 Oil temperature IV. MAINTENANCE 31 4.1 Oil grade 4.2 Oil level check replacement intervals 4.3 Oil change and Filter replacement intervals 4.3.1 Oil change and Oil filling capacity 4.3.2 Filter replacement

V. DIAGNOSTIC SYSTEMS 35 5.1 General 5.2 MOBIDIG 2001 5.3 Laptop Version 5.4 Multi-System 5000

ERGOPOWER


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ANNEX 3 WG-116/131/161/171, comprising: Tables: 1 Layout 2 Installation view – Front view 3 Installation view – Rear view Standard version 4 Installation view – Rear view with disc brake 5 Schedule of measuring points and connections 6 Oil circuit diagram (Forward 1st speed) 7 Gearbox diagram 8 Power flow - Forward speed 9 Power flow - Reverse speed 10 Electro- hydraulic control with proportional valves 11 Fully automatic control EST-37 Circuit diagram Standard - 6029 701 639 – 12 Controller DW-3 13 Controller ERGO II Abbreviations used in the text:

Abbreviation Description EST-37 Ergocontrol AEB Automated determination of the filling parameters ISK Inch sensor calibriation TCU Electronic control unit


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TECHNICAL DATA

3 WG-116 3 WG-131 3 WG-161 3 WG-171

Engine power: max. KW* 90 130 160 175

Turbine moment: max. Nm* 800 950 1 100 1 300

Engine speed: max. min-1* 2 600 2 600 2 600 2 600

Starting torque multipli-cation:

1,7 bis 3,0 1,7 bis 3,0 1,7 bis 3,0 1,7 bis 3,0

Engine-dependent Powertake-offs:

Torque:Speed:

max. Nmn

8001 x nMotor

8001 x nMotor

8001 x nMotor

8001 x nMotor

Gross vehicle weight max. t* 23 36 44 66

Lifting capacity max. t* 9 14 20 28

Mass (without oil): kg ca.** 300 300 300 300

* = dependent on Vehicle type and application** = dependent on the Transmission version

Description:The ZF-Transmissions 3 WG-116/131/161/171 are composed of a hydrodynamic torqueconverter and a rear-mounted multi-speed powershift transmission with integrated transfercase (see Table- 1).The torque converter is a wear-free starting device which is infinitely variable adapting itselfto the required situations (necessary input torque).

Input by direct mounting via diaphragm on the engine, or separate installation (input via uni-versal shaft) with DIN-, Mechanic- or Spicer-input flange.

The transmission can be shifted manually or fully-automatically by means of the Electronicunit EST-37A.

Torque converter:Unit size W 300 with torque multiplication.

Powershift transmission:3 Forward speeds and 3 Reverse speeds.

Output:The powershift transmission has between input and output shaft a center distance of 300 mm,and can be equipped with the following components:- with output flanges (rear-side) for different universal shafts- output (rear-side) with a disk brake as parking brake


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Power take-off:For the drive of an external oil pressure pump, an engine-dependent, coaxial power take-off isplanned.It allows the attachment of pumps with „SAE-C“ Connection.

Transmission ratio (mechanical)*

SPEED DRIVINGDIRECTION

Ratio

1 Forward 4,3312 Forward 2,2633 Forward 0,9941 Reverse 4,3452 Reverse 2,2713 Reverse 0,997

* = According to the Transmission version, other ratios are also possible.


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SCRIPTIONS ON A ZF-MODEL INDENTIFICATIONPLATE FOR ZF-HYDROMEDIA-REVERSING -TRANSMISSION

1 = Gearbox type2 = Gearbox Serial-No.3 = ZF-Parts List-No.4 = Total ratio of the Gearbox5 = Oil (Oil specification)6 = List of lubricants7 = Oil capacity8 = Customer no.

NOTES REGARDING THE SPARE PARTS ORDERS:

When ordering genuine ZF-Spare Parts, please indicate:

1. = Gearbox type2. = Serial-No.3. = ZF-Parts List-No.4. = Mark and type of vehicle5. = Denomination of the spare part6. = Spare parts-No.7. = Way of transport

When all of the above required indications are considered, errors in the delivery ofspare parts Orders can be avoided!

See Model identification Plate!

3

5

7

2

4

6

8

1


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IMPORTANT INSTRUCTIONS

Oil level check (see 4.2):In the cold start phase, the engine must be running about 2 – 3 minutes at idlingspeed and the marking on the oil dipstick must then be lying above the cold startmark.The oil level check in the transmission must be carried out at engine idling speedand operating temperature of the transmission (80° to 90° C).

At stationary engine, the oil level in the transmission is rising essentially, accord-ing to the installation conditions !

At every oil change, the ZF-Fine filter must be exchanged. In addition, ZF re-commends to start the autonomous calibration of the shifting elements (AEB).

The independent calibration of the shifting elements (AEB) must be started afterthe initial installation of the transmission and the Electronics in the vehicle at theVehicle Manufacturer and after every replacement of the transmission, the elec-trohydraulic control or the TCU in case of a failure.After every AEB-start the ISK (Inch-Sensor-Calibration) should be started forvehicles with inching device.

Put the Controller at the starting of the engine always to the Neutral position.At running engine and transmission in Neutral, the parking brake must be enga-ged or the service brake be actuated, to prevent the vehicle from rolling.

Prior to every start off, loosen the parking brake.

The engagement of the speed out of Neutral is only possible under the pro-grammed transmission input speed (turbine speed).Neutral position of the selector switch at higher vehicle speeds (above steppingspeed) is not admissible.Either a suitable gear is to be shifted immediately, or the vehicle must bestopped at once.

At stopped engine, there is on the Controller, despite a preselected gear, no po-wer flow between transmission and engine, i.e. the transmission is in the idlingposition.The parking brake must therefore be completely actuated !When leaving the vehicle, secure it additionally by brake blocks !

The towing speed must in no case be higher than 10 km/h, the towing distancenot longer than 10 km.It is imperative to observe this Specification because otherwise the transmissionwill be damaged due to insufficient oil supply !At a longer distance, the best solution would be to transport the defective vehiclewith a Low loader.


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Operating temperature behind the converter at least 65° and 100° C in conti-nuous operation, a short-time increase up to max. 120° C is permitted.

Temperature in the sump 60° - 90° C.By overstepping results by 105 ° C notice "WS" on the display.

In case of irregularities on the transmission, put the vehicle out of service andask for Specialists.

Protective measures for the ZF-Electronics at electrical operations on thevehicle:

At the following operations, the ignition must be switched off and the controlunit plug must be pulled off from the ZF-Electronics:

∗∗∗∗ At any kind of electrical operations on the vehicle.∗∗∗∗ At welding operations on the vehicle.∗∗∗∗ At insulation tests on the electric system.


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I. DESCRIPTION

1.1 Function of the Converter:

Function of a hydrodynamic Torque converter (Schematic view)

From engine

Condition at thetime of starting

Intermediatecondition

Condition in thecoupling point

TP = Torque pump wheel

TT = Torque turbine wheel

TR = Torque reaction member (Reaction

wheel)

Togearbox

NT = 0Vehicle standing still

nT = <<<<n Mot

nT = ≈≈≈≈ 0,8 n Mot

Figure-No. 1.1

The converter is working according to the Trilok-System, i.e. it assumes at high turbine speedthe characteristics, and with it the favourable efficiency of a fluid clutch.The converter is designed according to the engine power so that the most favourable operatingconditions are obtained for each installation case.

The Torque converter is composed of 3 main components:Impeller – Turbine wheel – Stator (Reaction member)

These 3 impellers are arranged in such a ring-shaped system that the fluid is streamingthrough the circuit components in the indicated order.Pressure oil from the transmission pump is constantly streaming through the converter. In thisway, the converter can fulfill its task to multiply the torque of the engine and at the same time,the heat created in the converter is dissipated via the escaping oil.The oil which is streaming out of the impeller, enters the turbine wheel and is there reversedin the direction of flow.According to the rate of reversion, the turbine wheel and with it also the output shaft is receiv-ing a more or less high reaction torque.The stator (reaction member), following the turbine, has the task to reverse the oil streamingout of the turbine once more and to deliver it under the suitable discharge direction to the im-peller.

Pump wheel Turbinewheel

TRReaction element(Reaction wheel)

1

1

1

1,5

<<<<1,5

2,5

1

TP

TT

0

<<<<2,5

ERGOPOWER

Off-Road Transmissions

and Axle Systems

Division

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Due to the reversion, the stator is receiving a reaction torque.

The relation turbine torque/pump torque is called torque multiplication. This is the higher, the

greater the speed difference of impeller and turbine wheel will be.

Therefore, the maximum torque multiplication is created at stationary turbine wheel.

With increasing output speed, the torque multiplication is decreasing. The adaption of the

output speed to a certain required output torque will be infinitely variable and automatically

achieved by the torque converter.

When the turbine speed is reaching about 80% of the pump speed, the torque multiplication

becomes 1,0 i.e. the turbine torque becomes equal to that of the pump torque.

From this point on, the converter is working similar to a fluid clutch.

A stator freewheel serves to improve the efficiency in the upper driving range, in the torque

multiplication range it is backing-up the torque upon the housing, and is released in the clutch

range.

In this way, the stator can rotate freely.

1.2 Powershift transmission:

The multi-speed reversing transmission in countershaft design is power shiftable by hydrauli-

cally actuated multi-disk clutches.

All gears are constantly meshing and carried on antifriction bearings.

The gear wheels, bearings and clutches are cooled and lubricated with oil.

The 3-speed reversing transmission is equipped with 5 multi-disk clutches.

At the shifting, the actual plate pack is compressed by a piston, movable in axial direction,

which is pressurized by pressure oil.

A compression spring takes over the pushing back of the piston, thus the release of the plate

pack. As to the layout of the transmission as well as the specifications of the closed clutches

in the single speeds, see Table-1, 5 and 6.

1.3 Transmission control:

Transmission control, see Schedule of measuring points, Oil circuit diagram ans Electro- hy-

draulic control unit see Table-4, 5 and 6.

The transmission pump, necessary for the oil supply of the converter, and for the transmission

control, is sitting in the transmission on the engine-dependent input shaft.

The feed rate of the pump is

Q = 85 l /min, bei nMotor = 2000 min -1

⇒ 3 WG-116/131

Q = 105 l /min, bei nMotor = 2000 min -1

⇒ 3 WG-161/171

This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the ZF-

Fine filter – the filter can also be fitted externally from the transmission – to the main pressure

valve.

If because of contamination, resp. damage, the through-flow through the ZF-Fine filter is not

ensured, the oil will be directly conducted via a filter differential pressure valve (bypass valve

∆p= 5,5+3 bar) to the lubrication.

In this case, an error indication is shown on the ZF-Display.


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In this case, an error indication is shown on the ZF-Display.

ZF-Fine filter:Filtration ratio according to ISO 4572: ß30 > 75 ß15 = 25 ß10 = 5.0Filter surface at least: 6700 cm2 Dust capacity according to ISO 4572 at least: 17 g

The five clutches of the transmission are selected via the 6 proportional valves P1 to P6 (P1will not be under current at the 3-speed version, i.e. without function !!).The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6),follow-on slide and vibration damper.

The control pressure of 9 bar for the actuation of the follow-on slides is created by the pressu-re reducing valve. The pressure oil (16+2 bar) is directed via the follow-on slide to the re-spective clutch.

Due to the direct proportional selection with separated pressure modulation for each clutch,the pressures to the clutches, which are engaged in the gear change, will be controlled. In thisway, a hydraulic intersection of the clutches to be engaged and disengaged becomes possible.This is creating spontaneous shiftings without traction force interruption.

At the shifting, the following criteria will be considered:- Speed of engine, turbine, central gear train and output.- Transmission temperature.- Shifting mode (up-, down-, reverse shifting and speed engagement out of Neutral).- Load condition (full and part load, traction, overrun inclusive consideration of load cycles

during the shifting).

The main pressure valve is limiting the max. control pressure to 16+2,5 bar and releases themain stream to the converter and lubricating circuit.In the inlet to the converter, a converter safety valve is installed which protects the converterfrom high internal pressures (opening pressure 11+2 bar).Within the converter, the oil serves to transmit the power according to the well-known hydro-dynamic principle (see Chapter Torque converter 1.1).To avoid cavitation, the converter must be always completely filled with oil.This is achieved by a converter pressure back-up valve, rear-mounted to the converter, with anopening pressure of at least 4,3+3 bar.The oil, escaping out of the converter, is directed to a heat exchanger.The selection and definition of the heat exchanger must be carried out according to our Instal-lation specification for hydrodynamic powershift transmissions by the Customer on his ownresponsibility.

The heat exchanger is not within the scope of supply of the ZF Passau GmbH.From the heat exchanger, the oil is directed to the transmission and there to the lubricating oilcircuit, so that all lubricating points are supplied with cooled oil.In the Electrohydraulic control unit are 6 pressure regulators installed – see Table-10.

The allocation of the pressure regulators to the single speeds can be seen on the Tables 5 and6.


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1.4 Controller

1.4.1 General:

��Due to the great number of the available Controllers, the precise Technical Datamust be taken from the respective installation drawing.

1.4.2 Controller DW-3- see Table-12

The Controller is designed for the mounting on the steering column left side. By a rotativemotion, the positions (speeds) 1 to 4 are selected by tilting the lever, the driving direction(Forward (F) – Neutral (N ) – Reverse (R).The DW-3 Controller is also available with integrated Kickdown pushbutton.

For the protection from unintended start off, a Neutral interlock is installed:Position „N“ – Controller lever blocked in this positionPosition „D“ – Driving

Controller DW-3

D

F

N

R

N

Figure-No.: 1.4.2

1.4.3 Controller ERGO II- see Table-13

This lever will be installed in the Wheel loader instead of the operating lever for the hydraulicsystem for implement operation.By pushing the arrow button „Forward“ and „Reverse“, the driving direction will be selected,the Buttons „+“ and „-„ are preselecting the driving range.The indication for gear and driving direction is shown on the Display (see 1.5).By means of the „N“-Button, the transmission is shifting to Neutral.Gear limitation, if second cabin is activated an the all-wheel drive is engaged.

Another Button on the operating field allows the connection of an electric shovel-horizontalRegulation (Shovel-Neutral). Another function button is installed on the back. It serves, ac-cording to the programming, as Kickdown button, Down-shift button or Release button for thestart off.

Gear positions Type plate

R

N

F


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Controller ERGO II

+ -N

Figure-No.:1.4.3

1.5 Display

1.5.1 General:

The Display can be used with all Controller types, e.g. with the DW-3 or ERGO II for Wheelloaders, Lift trucks, RoRo trucks as well as with the VTS-3, SG-6 or D7 for Cranes, Dumpers,Graders and Rail vehicles.

1.5.2 Possible Indications on the Display

Display

left central right h f e d Side Side Side

a b c g

Figure-No.: 1.5.2

Spec. charact. Displaya, f Automatic range (up- and downshifting)b, c, d, e Preselected gearg EST-37A has recognized an error, is flashingh Disturbance im AEB mode / Calibration ISKLeft Side For the moment still without functionCentral andRight Side

On the two alphanumeric 16-segment displays, the EST-37A issues theactual state of gear and driving direction. Besides, a two-digit error codewill be indicated via these two segments.


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Display of the Driving direction:(right Side)

V : ForwardN: NeutralR: Reverse

Display of the engaged gear:(central Side)

Display 1, 2, 3

Waiting for Controller-Neutral: Indication on the Display: NN (central and right Side).In this condition, Neutral is pending on transmission.To engage a gear, at first Neutral must be shifted onthe Controller before the electronics allows to engage agear again.

Preselected Driving range:(Special characters b, c, d, e)

The number of the lines indicates the driving range,resp. the gear preselection:1 Bar: Manual Mode 1 speed2 Bars: Manual Mode 2 speed3 Bars: Manual Mode 3 speed

Display Manual/ Automatic:(Special characters a, f)

If the two Symbols a , f (Arrows) and the bars b, c, d, eare indicated, the system is in the Automatic mode(automatic up- and downshiftings).

��If the Arrows (a, f) are flashing, the KD (Kick-Down) – Mode is activated.

Display of the Cold-start phase: Transmission remains in Neutral

Bars are flashing: Downshifting mode active

Error display: If the system is recognizing an error, the spanner (Spe-cial symbol „g“) is flashing.If Neutral is preselected on the Controller, a two-digiterror number appears on the two alphanumeric indica-ting positions (central and right Side).

If more than one error is pending, the different errornumbers will be indicated one after the other on theDisplay in cycles (about 1 second).

��The error code will be only then indicated ifthe Controller is in Neutral !


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Warning display: At exceeding the warning threshold Temperature –Sump / behind the Converter and the warning thres-hold Speed – Engine, changes the indication on theDisplay to the actual gear and the corresponding war-ning indicator.

��If several warnings are simultaneously active,only the warning with the highest priority willbe indicated.

Warningcode

Warning Priority

WT Temperature behind Converter 1WS Temperature in the Sump 2WE Engine speed 3

Display PN Driving direction F or R selected whilst the parkingbrake is actuated.Transmission in Neutral until parking brake will bereleased.

After the release of the parking brake, the ve-hicle begins to roll.

F or R flashing Driving direction F or R selected, whilst the turbinespeed is too high.

��Speed will be engaged when the turbine speedisdecreasing.

Display EE Indication on Display: EE (central and right side).In this state, the Display has a timeout, i. e. it is recei-ving no Data from the EST-37A.

Main reasons:- EST-37A is in TOTAL RESETTING MODE

(e.g. because of output train disconnection or external power supply at the lines to the gear-solenoid valves).- EST-37A without supplyData line not correctly connected, etc.

1.5.3 Error code definition:

The error codes are composed of two hexadecimal numbers:The first number indicates the kind of signal, the second number the signal and the kind oferror.

��Since there are different Software versions for the Customers, the listing of the errorcodes must be taken from the Documentation of the Vehicle Manufacturer.

ERGOPOWER


and Axle Systems

Division

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First Number Meaning of the Number

1 hex Digital input signal

2 hex Analog input signal

3 hex Speed signal

4 hex CAN signal error



7 hex Analog current output signal

8 hex Analog current output signal

9 hex Digital output signal

A hex Digital output signal

B hex Transmission error, Clutch error

C hex Logical error

D hex Power supply

E hex Highspeed signal

F hex General error

��

For the EST-37A, a general Diagnostic and Trouble shooting Specification is available,

for which the following Order-No. has been defined:

5872 993 025 GERMAN

5872 993 026 ENGLISH

This Diagnostic and Trouble shooting Specification can be requested under the follow-

ing address:

ZF Passau GmbH

Abt. ACI

Donaustr. 25 – 71

94034 Passau

1.6 Elektronic Control unit TCU

The electrohydraulic transmission control can be automated by connection on the electronic

TCU.

The basic functions of the automatic system are the automatic shifting of speeds, adaption of

the optimum shifting points, the comfortable kickdown function as well as comprehensive

safety functions in relation to operating errors and overloadings of the power-transmitting

components with a comprehensive fault storage.

The Control units can be programmed customized and vehicle-specific in a large spectrum,

Control parameter can be logically chained, and also Special functions such as gear limitation,

Converter functions can be integrated.


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Installation position of the TCU

Figure-No..: 1.6 B1Installation position of the TCU

Figure-No.: 1.6 B2

��Because of the great number of available TCU, the precise Technical Data must betaken from the corresponding Installation drawing.

��The installation position of the TCU can be at random. As an advantage, the ZF re-commends the Version illustrated in the Figure-No.: 1.6 B1.

90° 90° 90° 90°

209

50

100

100

Minimum Distance to disengage the plug

ZF-Type plate


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The installation of the TCU must be realized on a protected point in the cabin.An overfloating with water must be excluded. Besides, the penetration of water viathe plug connection must be prevented by corresponding measures on the cable har-ness.

1.7 Electronic Controls for ZF-Powershift transmissions:

1.7.1 General:

��Because of the different configurations of the electronic transmission controls at thevarious vehicles, the corresponding documentation must be taken from the operatingInstructions of the Vehicle Manufacturer or from the Technical Data sheet of theconcerned Parts List Versions. In these are also indicated the respective circuit dia-gram (see Sample Table-11) - and the connection diagram (upon request, these In-formations can be asked for at the ZF Passau).According to the type of vehicle, the wiring will be performed according to the wi-ring diagrams.The corresponding electric circuit diagrams (proposals) will be realized by ZF.Upon request, the wiring can be also supplied by ZF.If the wiring will be realized by the Vehicle Manufacturer, it must be in accordancewith the ZF-Requirements (see Installation Specification).

1.7.2 Description of the Basic functions:

The Powershift transmission of the Ergopower-Series 3 WG-116/131/161/171 is equippedwith the Electronic control unit EST-37A, developped for it.

For Wheel loaders, Lift trucks and RoRo Trucks, the ZF has developped with the ControllersDW-3 and ERGO II a special Controller configuration.

The system is processing the desire of the driver according to the following criteria:

**

*****

Gear determination depending on controller position, driving speed and load condition.Protection from operating error as far as necessary, is possible via electronic protection(programming).Protection from over-speeds (on the base of engine and turbine speed).Pressure cut-off possible (vehicle-specific, only after contact with ZF).Change-over possibility for Auto- / Manual mode.Downshifting functions possible.Electronic inching

Legend ref. Figure-No.: 1.7.2

1 = Acoustic / optical warning (Option)2 = Display3 = Controller DW-3 (optionally also with Controller e. g. ERGO II possible)


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4 = Power supply connection5 = Switch for enable inchen (Option)6 = Switch for driving program Manual/Automatic (Option)7 = Switch for selection starting gear (Option)8 = Switch for LIMP HOME monitoring ON/OFF (Option)9 = TCU10 = CAN-Connection11 = Wiring12 = Diagnosis Mobidig 2001 only for ZF-Service Stations13 = Diagnosis Laptop with ZF-Diagnostic system Testmann14 = Cable to Inductive transmitter Speed Central gear train15 = Cable to Inductive Speed Engine16 = Cable to Inductive transmitter Speed Turbine17 = Cable to Temperature measuring point behind the Converter „No. 63“18 = Cable to Plug connection on the electrohydraulic Control unit19 = Cable to filter contamination switch20 = Cable to Speed sensor Output21 = Cable from angle sensor/inch-sensor (Option)22 = Ergopower Transmission 3 WG-116/131/161/171

Family package of the EST-37A

Figure-No.: 1.7.2

20

6

1

2

34

5

8

9 10

14

15

16

18

117

13

12

17

19

2122


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1.7.3 Independent calibration of the Shifting elements (AEB)

The AEB has the task to compensate tolerances (plate clearance and pressure level) which areinfluencing the filling procedure of the clutches. For each clutch, the correct filling parametersare determined in one test cycle for:

• Period of the quick-filling time• Level of the filling compensating pressure

The filling parameters are stored, together with the AEB-Program and the driving program inthe transmission electronics. Because the Electronics will be separately supplied, the AEB-Cycle must be started only after the installation of both components in the vehicle, thus ensu-ring the correct mating (Transmission and Electronics).

��At any rate, the AEB-Cycle must be carried out at the Vehicle Manufacturer prior to thecommissioning of the vehicles. It is imperative, to respect the following Test conditions:

- Shifting position Neutral- Engine in idling speed- Parking brake actuated- Transmission in operating temperature

��After a replacement of the transmission, the electrohydraulic control or the TCU in thevehicle, the AEB-Cycle must be as well carried out again.

The AEB-Cycle continues for about 3 to 4 minutes. The determined filling parameters arestored in the EEProm of the Electronics. In this way, the error message F6 shown on the Dis-play will be cancelled also at non-performed AEB.

��For the start of the AEB-Cycle, there are principally two possibilities:

1. Start of the AEB by separate Tools which are connected on the diagnostic port

of the wiring. Following Tools for the AEB start will be offered by the ZF Service.: - Mobidig 2001 (see Point 5.2 – Diagnostic systems) - Testmann (see Point 5.3 – Diagnostic systems)- AEB Starter

Order-No.: 0501 211 778

The Special Tool, developped by the ZF for it can be used only for the starting of the AEB !

(see Figure-No.: 1.7.3)

Figure-No.: 1.7.3 B1

2. Start of the AEB by operating elements on the vehicle.For it, a CAN-Communication between transmission and vehicle electronics is

necessary.


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��At the operating of the transmission, the paper friction linings, installed in the Ergopo-wer transmissions are settling, i.e. the plate clearance becomes creater.Because these settling appearances can affect the shifting quality, ZF recommends torepeat the AEB-Cycle at the Maintenance intervals (see 4.3.1).

��At a deterioration of the shifting quality, the ZF recommends likewise as first measureto repeat the AEB-Cycle.

��ISK (Inch-Sensor-Calibration) should also be carried out after every AEB-Start (in thiscontext refer to 1.7.6).

1.7.4 Down-Shift functions (Down-Shift Button)

If necessary, it is possible to select from 3 different possibilities:

Down-Shift Button – 1:

Function: The downshifting from the second speed (mode manual) into the first speed isperformed at the first actuation.At a second actuation, the upshifting from the first speed into the second speedfollows again.

Down-Shift Button - 2 (Ouick-Shift Button)

Function: The range limitation on the actual speed will be performed at the first actuation,after a second actuation, the full range is existing again.

Down-Shift Button - 3:

Function: Every actuation is leading to a downshifting for one speed.

��The Down-Shift Button (pushbutton) must be in all 3 possibilities provided bythe Customer-side, if as Controller the DW-3 or ERGO II with integratedDown-Shift Button will not be used.

1.7.5 Pressure cut-off

In order to provide, e.g. at Shovel loaders, the full engine power for the hydraulic system, thecontrol can be enlarged for the function of a pressure cut-off in the 1st and 2nd speed. In thisway, the pressure in the powershift clutches will be cut-off, and the torque transmission in thedrive train will be eliminated by it. This function will be released at the actuation of a switch,arranged on the brake pedal. For a soft restart, the pressure will be build-up via a freely pro-grammable characteristic line.


24

1.7.6 Inching device

This function is especially suitable for Lift trucks. It allows to reduce the driving speed infini-tely variable without modification of the engine speed in such a way that driving with a verylow speed will be possible. In this way, the driver can move the vehicle very exactly to a de-termined position.At the same time, an important part of the engine power for the output of the hydraulic systemis at disposal by the high engine speed.

Operation is carried out by a separate inching pedal, where an angle of rotation sensor ismounted.By means of the proportional valve technology the TCU regulates the pressure in the drivingdirection clutch in such a way that the driving speed is adjusted in accordance with the inchrotating angle sensor position. Clutch overloading is avoided thanks to the electronic protec-tion.

��After each new adjustment of the inch linkage , the ISK (Inch Sensor Calibration) mustbe carried out.

During the inch calibration modus the position of the inch pedal in neutral position andwith full actuation is controlled by the calibration process and stored in the TCU.

��The inching function is only active after successful completion of AEB and ISK start.

1.7.7 Special functions

According to the desires of the Vehicle Manufacturer, further additional functions can be pro-grammed. Functions such as can be realized:

* Selection of a Parking brake* Automatic Neutral shifting at vehicle standstill* Gear range limitation depending on determined Input signals* Blocking of the speed engagement beyond a determined Engine speed* Upshifting prevention in the overrunning range

Further available Special function upon request after contact with the ZF.

ERGOPOWER


and Axle Systems

Division

25

II. INSTALLATION SPECIFICATION

This Specification for the installation of hydrodynamic Powershift transmissions of the Ergo-

power-Series is the basis for the technically faultless installation of these transmissions in the

vehicle. The Installation Specification is part of the Transmission Documentation and must be

absolutely respected.

A faulty installation of the transmission into the vehicle, can

* affect the operating quality,

* cause malfunctions of the transmission,

* lead to transmission damages, resp. transmission failures.

Responsible for the correct installation of the transmission is the Vehicle Manufacturer.

ZF does not admit any guarantee or warranty claims for damages

which has been caused by a faulty installation.

In order to assist the Customer in case of new, resp. initial applications, the ZF carries out by

authorized personnel a transmission installation check. On this occasion, all transmission-

specific installation features are examined and the Vehicle Manufacturer, resp. the Equipment

Manufacturer will be informed about the encountered defects.

At improperly installation, ZF reserves itself the right to acknowledge no guarantee for the

installed ZF-Products.

For damages, caused by defects for which the Vehicle Manufacturer is responsible, and could

not be discovered at the installation examination by ZF-Personnel, the Vehicle Manufacturer

alone is liable.

This Installation Specification

0000 702 270 DEUTSCH

0000 702 271 ENGLISCH

can be requested under the following address:

ZF Passau GmbH

Dep. ACETS

e-mail: [email protected]

Donaustr. 25 – 71

94034 Passau

ERGOPOWER


27

III. OPERATION 3.1 Driving preparation and Maintenance: Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filter as well as the pipes must get filled with oil. According to these cavities, the quantity of oil to be filled in, is greater than at the later oil fil-lings in the course of the usual Maintenance service.

! Because the converter and also the heat exchanger, installed in the vehicle, as well as the pipes can empty at standstill into the transmission, the Oil level check must be carried out at engine idling speed and operating Temperature of the transmission (see Chapter Oil level check 4.2).

At the oil level check, the prescribed safety directions according to § 6 of the regulations for the prevention of accidents for power plants in Germany, and in all other countries, the respective national regulations have to be absolutely observed. For example, the vehicle has to be secured against rolling by blocks, articulated vehicles additionally against unintended turning-in.

3.2 Driving and Shifting:

! Which control lamps in the INFOCENTER (dashboard) are illuminated for the functional control, can be different from Vehicle Manufacturer to Vehicle Manufac-turer. Control elements and displays can be from the ZF, however can be also customer-specific products; the precise specifications must therefore be taken from the Oper-ating Instructions of the respective Vehicle Manufacturer.

- Neutral position: Neutral position will be selected via the Controller. After the ignition is switched on, the electronics remains in the waiting state. By the position NEUTRAL of the Controller, resp. by pressing the pushbutton NEUTRAL, the EST-37A becomes ready for operation. Now, a gear can be engaged. - Starting: The starting of the engine has always to be carried out in the NEUTRAL POSITION of the Controller. For safety reasons it is to recommend to brake the vehicle securely in position with the parking brake prior to start the engine.

After the starting of the engine and the preselection of the driving direction and the gear, the vehicle can be set in motion by acceleration.

ERGOPOWER


28

At the start off, the converter takes over the function of a master clutch. On a level road it is possible to start off also in higher gears. - Upshifting under load. Upshifting under load will be then realized if the vehicle can continue to accelerate by it. - Downshifting under load. Downshifting under load will be then realized if more traction force is needed. - Upshifting in overrunning condition.

In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling po-sition , if the speed of the vehicle on a downgrade should not be further increased.

- Downshifting in overrunning condition. Downshifting in overrunning mode will be then carried out if the vehicle should be retaded. If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be stalled. On a level and horizontal roadway it is possible that the vehicle begins to crawl, because the engine is creating at idling speed a slight drag torque via the con-verter. It is convenient to brake the vehicle at every stop securely in position with the parking brake. At longer stops, the Controller has to be shifted to the NEUTRAL POSITION. At the start off, the parking brake has to be released. We know from experience that at a con-verter transmission it might not immediately be noted to have forgotten this quite normal op-erating step because a converter, due to its high ratio, can easily overcome the braking torque of the parking brake. Temperature increases in the converter oil as well as overheated brakes will be the conse-quences to be find out later. Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not admissible. Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.

! Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not admissible.Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.

3.3 Cold start: At an oil temperature in the shifting circuit < -12° C, the transmission must be warmed-up for some minutes. This must be carried out in Neutral with an increased engine speed (about 1500 min-1). Until this oil temperature is reached, the Electronics remains in Neutral, and the symbol of the cold start phase will be indicated on the ZF-Display. Indication on the Display : After the indication on the ZF-Display is extinguished, the full driving programm can be util-ized out of „NEUTRAL“.

ERGOPOWER


29

3.4 Transmission control in the Driving mode Automatic:

! Precise Informations about the design of the Controllers as well as the speeds shifted in the single driving ranges, must be taken from the Operating Instructions belong-ing to the vehicle.

A manual intervention into the automatic shift sequence is only then practical if the roadway condition or the configuration of the ground is suitable. 3.5 Stopping and Parking: Since due to the converter there is no rigid connection existing from the engine to the axle, it is recommended to secure the vehicle on upgrades, resp. downgrades against unintended roll-ing not only by applying the parking brake but additionally by a block on the wheel, if the driver has the intention to leave the vehicle. 3.6 Towing: See Important Instructions – Page 10.

3.7 Oil temperature:

The oil temperature in the transmission sump is monitored by a temperature sensor in the electrohydraulic control unit.

The service temperature in the sump of 60° - 90° C must not be exceeded!

! By overstepping results by 105 ° C notice "WS" on the display in the cabine.

At a trouble-free unit and an adequate driving mode, a higher temperature will not occour. The notice "WS" results at the display, the vehicle has to be stopped and controlled for exter-nal oil loss and the engine must run with a speed of 1200 – 1500 min-1 at NEUTRAL POSITION of the transmission.

Now, the temperature must drop quickly (in about 2 – 3 minutes) to normal values. If this is not the case, there is a trouble pending, which must be eliminated prior to continue working.

The monitoring of the oil temperature is additionally realized behind the converter with an indication on the ZF-Display or analog in the INFOCENTER.

Operating temperature behind the converter at least 65° C and 100° C in continuous opera-tion, a short-time increase up to max. 120° C is permitted.

! The temperature is measured on the measuring point „63“

(see Schedule of measuring points – Table-5 !)

ERGOPOWER


31

IV. MAINTENANCE 4.1. Oil grade:

! Permitted for the Powershift transmissions 3 WG-116/131/161/171 are oils accord-ing to ZF-List of lubricants TE-ML 03.

! This List of lubricants will be updated every three months and can be requested, resp. inspected as follows: - At all ZF-Plants - At all ZF-Service Stations - Internet http://www.zf.com Service /Technical Information

4.2 Oil level check (measurements only with running engine):

At the oil level check, the prescribed safety directions according to § 6 of the rules for accident prevention for power plants in Germany, and in all other countries the respective national regulations have to be absolutely respected. For example, the vehicle has to be secured against rolling with blocks, articu-lated vehicles additionally against unintended turning-in.

The oil level check must be carried out as follows: - Oil level check (weekly) - At horizontally standing vehicle - Transmission in Neutral position „N“ - In the cold start phase, the engine must be running about 2 – 3 minutes at idling speed, and

the marking on the oil dipstick must then be lying above the cold start mark „COLD“ (see Figure-No. 4.2 B2) - At operating temperature of the transmission (about 80° - 90° C) -

! With engine idling speed

all measurements must be carried out with low engine idling speed.

- Loosen oil dipstick by counterclock rotation, remove and clean it

- Insert oil dipstick slowly into the oil level tube until contact is obtained, and pull it out again. - On the oil dipstick, the oil level must be lying in the zone „HOT“ (see Figure-No.: 4.2 B2) - Insert the oil dipstick again, and tighten it by clockwise rotation

! If the oil level has dropped in operating temperature condition below the „HOT“ Zone, it is absolutely necessary to replenish oil according to the ZF-List of lubri-cants TE-ML-03. An oil level above the „HOT“ marking, is leading to a too high oil temperature.

! The oil dipstick and the oil filler tube can have different lengths and shapes, accord-ing to the Transmission version. Besides, the mounting on the transmission can be optionally realized on the converter side or on the rear side.(In this Illustration, the mounting of the oil dipstick is illustrated on the rear side).


32

Figure-No.: 4.2 B1Legend:

1 = Oil filler tube with oil dipstick (rear side)2 = Oil drain plug M38x1,53 = Attachment possibility oil level tube with oil dipstick (converter side)4 = Filter head5 = ZF-Fine filter (Pressure filter)

Oil dipstick

MIEASURED AT LOWIDLING-NEUTRAL

HOT COLD

Figure-No.: 4.2 B24.3 Oil change and Filter replacement intervals:

��First oil change after 100 operating hours in service.Every further oil change after 1000 operating hours in service, however at leastonce a year !At every oil change, the ZF-Fine filter (pressure filter) has to be replaced.

4.3.1 Oil change and Oil filling capacity:

The oil change has to be carried out as follows.At operating temperature of the transmission,horizontally standing vehicle open the oil drain plug and drain the used oil.

Bereich„HOT“

3

4

1

2

5


33

- Clean oil drain plug with magnetic insert and surface on the housing and install againalong with O-ring.

- Fill in oil (about 20 liters) according to ZF-List of lubricants TE-ML 03.(Sump capacity, external oil capacities e.g. in the heat exchanger, in the lines etc. are

dependent on the vehicle).The indicated value is a guide value.

��It is imperative to pay attention to absolute cleanliness of oil and filter !Binding is in any case the marking on the oil dipstick !

- Start the engine – idling speed- Transmission in Neutral position „N“- Top up oil up to the marking „COLD“- Brake the vehicle securely in position and warm up the transmission- Shift all Controller positions through- Check the oil level once more and top up oil once more if necessary- On the oil dipstick, the oil level must be lying in the Zone „HOT“ (see Figure-No.: 4.2 B2)- Insert the oil dipstick again and tighten it by clockwise rotation.

��At the initial filling of the transmission has to be considered that the heat exchanger,the pressure filter as well as the pipes must get filled with oil.According to these cavities, the oil capacity to be filled in is greater than at the lateroil fillings in the course of the usual Maintenance service.

��ZF recommends, to start the AEB at every oil change (see 1.7.3).

4.3.2 Filter replacement:

At the replacement of the ZF-Filter in the main oil stream, pay attention that no dirt or oilsludge can penetrate into the circuit. Besides, the parking brake has to be covered, resp. pro-tected from oil wetting.At the mounting of the filter, any exertion of force has to be avoided.

��The filters are installed separately from the transmission in the vehicle !

��Treat the filter carefully at the installation, the transport and the storage !Damaged filters must no more be installed !

��The filter differential pressure valve (bypass valve) is equipped with a maintenance-switch (opening switch) which is informing the driver about the contamination ofthe ZF-Fine filter.At the lighting up of the symbol, the ZF-Fine filter must be replaced.

The mounting of the filter must be carried out as follows:- Cover the gasket with a small amount of oil.- Screw the filter in until contact with the sealing surface is obtained and tighten it now by hand about 1/3 to 1/2 turn.


35

V. ZF-DIAGNOSTIC SYSTEMS

5.1 General:

The Control electronics EST-37A for the Transmission Series Ergopower is equipped with adiagnostic package, which makes the Trouble shouting and the Repair of damages easier forthe Service.The Electronics is able to monitor the states of certain inputs and outputs.If the Electronics recognizes at it an error, it stores an error code in the fault storage(EEPROM) and is transmitting the error code also to the vehicle controller of the Vehicle Ma-nufacturer.The ZF-Diagnostic and Programming systems MOBIDIG-2001 (see 5.2) and LAPTOP-Version (see 5.3) are needed for the following applications:

��Diagnosis - Read actual errors

- Read fault storage- Cancel fault storage

AEB - Independent calibration of the shifting elementsTesting Inputs and Outputs - Check Outputs

- Check Inputs- Check systems downtime- System test drive

Additionally for the Diagnosis can be used the Multi-System 5000 (see 5.4) with correspon-ding sensor system for pressure, temperature, speed, through-flow, current transformer etc.

5.2 ZF - MOBIDIG 2001

��The ZF-Diagnostic system MOBIDIG 2001 is only reserved to ZF-Service Stations.All necessary, transmission-specific Data for a quick and comprehensive Diagnosiscan be retrieved with this Diagnostic system.

The Data are stored on CD-Rom and will be updated 2 – 3 times a year.It is universally to be used for all diagnosis-capable ZF-Vehicle systems.

MOBIDIG 2001 withZF-Diagnostic Software

Diagnostic Software with Operatorguidance

6008 307 001

Terminal tester 68-pinFor the test of single control signals, lineconnections etc.

6008 304 038

Figure-No.: 5.2


36

5.3 Laptop Version:

Specialized Dealers Pentium Laptop min. 90 MHz

Windows 95/98 or NT

Basic-SoftwareTestman WIN 95/98 or NT

6008 308 901

RS-232 Connecting cableLaptop ⇔ DPA-04I

6008 308 601

Programming adapterDPA-04I

6008 308 600

Adapter cableDPA-04I ⇔ EST-37A6029 017 005

Diagnostic set5870 221 179WIN 95/98

orNT

Diagnostic Software WG-116/131/161/171

6008 308 007 GERMAN

6008 308 107 ENGLISH

6008 308 207 FRENCH

Terminal Tester 68-pinFor the test of single controlsignals, line interruptions etc.

6008 304 038

Figure-No.:5.3


37

5.4 ZF-Multi-System 5000:

Multi- System 5000

Measuring box with corresponding sensor sy-stem for pressure, temperature and speed withoutprinter.

5870 221 280

Multi- System 5000

Measuring box with corresponding sensor sy-stem for pressure, temperature and speed withprinter.

5870 221 281Multi - System 5000

Portable measuring instrument without accesso-ries.

5870 221 250

Accessories:Sensor system for through-flow, current transformer etc.

Current transformer:

5870 221 284

Turbine – Metering tubes:

15 – 300 l/min = 5870 221 13325 – 600 l/min = 5870 221 134

Figure-No.: 5.4

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Page 2 from 2

Coding

• Pressure regulator active Engaged clutchesDriving direction Speed Y1 Y2 Y3 Y4 Y5 Y6Forward 1 • • K1 KV

2 • • KV K23 • • K3 KV

Reverse 1 • • KR K12 • • KR K23

Not

use • • KR K3

Neutral dEngaged clutches K4 KR K1 K3 KV K2Position on the valve block F E D C B AConsecutively No. of the measurement points 60 55 56 58 53 57

OIL CIRCUIT DIAGRAM 3 WG-116/131/161/171 FORWARD 1st SPEED TABLE-6The marked positons (e.g. 53) correspond with the positions on the table-5!

• Pressure regulator active Engaged clutchesDriving direction Speed Y1 Y2 Y3 Y4 Y5 Y6Forward 1 • • K1 KV

2 • • KV K23 • • K3 KV

Reverse 1 • • KR K12 • • KR K23

Not

use • • KR K3

Neutral dEngaged clutches K4 KR K1 K3 KV K2Position on the valve block F E D C B AConsecutively No. of the measurement points 60 55 56 58 53 57

Page 1 from 2

Legend:

WT = Heat exchangerWGV = Converter back pressure valve 4,3+3 barWSV = Converter safety valve 11+2 barHDV = Main pressure valve 16+2,5 barRV-9 = Pressure reducing valve 9 barNFS = Follow-on slideD = Vibration damperB = OrificeP1 = Not usedP2 = Proportional valve KRP3 = Proportional valve K1P4 = Proportional valve K3P5 = Proportional valve KVP6 = Proportional valve K2Y1...Y6 = Pressure regulatorsTEMP = Temperature sensorUEDV = Pressure relief valve 40±5 barWS = Maintenance switchFDV = Filter pressure differential valve (Bypass-valve) ∆p=5,5 bar

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Legend:

AN = Input

KV = Clutch forward

KR = Clutch reverse

K1 = Clutch 1st speed

K2 = Clutch 2nd speed

K3 = Clutch 3rd speed / Output

PTO = Power take-off

Driving direction Speed Clutch

1 KV/K1

2 KV/K2

Forward

3 KV/K3

1 KR/K1

2 KR/K2

Reverse

3 KR/K3

AN

K1

KR

KV

K2

K3/AB

PTO

GEARBOX DIAGRAM 3 WG-116/131/161/171

TABLE-7

Diagram Clutches

KV

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